3. Design Requirements
• Passenger transport
• 250 – 400 passengers depending on configuration
• Operating altitude = 50,000 ft
• Reduced fuel consumption, 20% less than 777
• Range min 4500nm
• High speed subsonic M=.95
• Major maintenance span increased 25% over B777
4. Challenges
Cruising altitude at 50,000 ft
Air has lesser density; Reduced max velocity
High speed subsonic M=0.95
Drag coefficient dramatically increases at Mach number
M = 0.9 to 1
Major maintenance span increased 25%
Maintenance frequency is subject to Operator
discrepancy
38. Inboard Profile
Cabin Length – 173’-11’’
8 Exits – 6 Door and 2 Over the wing
8 Lavatories
39. Cabin Layout
305 Maximum passenger capacity
3-class Configuration
First class cabin at 60in pitch
24 seats
Business class cabin at 38in pitch
54 seats
Economy class cabin at 31-32in pitch
227 seats
40. Cabin Cross Section
Cabin Max Width
14’-4.9”
Maximum Height
6’-9”
Economy class seating
7 abreast configuration
Seat width 18.2”
41. Cabin Cross Section
Business class seating
6 abreast configuration
Seat width 22”
First class seating
4 abreast configuration
Seat width 29”
42. Inputs
- Atmospheric Conditions
- Chosen Sweep Angle, Thickness
ratio, Taper Ratio, CLmax
- Wing Loadings and Aspect Ratios
- Initial Gross Weight estimate
Computed Values
- Surface Areas
- Wing and Tail Spans and Areas
- Chord Lengths
- Mean Aerodynamic Chords
1) Required Thrust
for Takeoff
Calculated required thrust for
takeoff (T1) using selected CLmax
and predicted GW
2) Engine Sizing
Calculate size of engines from
required power
Initial Flat Plate
Drag Estimate
Calculate equivalent flat-plate
area and drag from aircraft
parameters
3) Thrust
Calculate Thrust for Vmax (T2)
during takeoff, and thrust at
ceiling altitude (T3)
Is T1 greater than
or equal to T2,
T3?
NO
Re-iterate with a thrust
greater than previously
calculated thrust
IF YES, Engine
size is correct!
Estimate
Empty Weight
Calculate using Raymer
weight equations
Calculate fuel
required for
design mission
Calculate the
Gross Weight
- Add payload, crew, fuel and
empty weight
Is the Calculated
Gross Weight =
Guessed Gross
Weight?
YES. Feasible
Design!
NO
Re-iterate using
newly calculated
Gross weight
Iterative Sizing
45. Aircraft Systems
Aircraft Systems have been upgraded to the new
technology of the Boeing 777x
Integrated Systems – Critical Systems are integrated into
one cabinet
Central Maintenance Computer
Thrust Management System
Flight Data Recorder System
Primary Display System
Data Communication Management
Flight Management Systems
46. Fly-By-Wire (FBW)
Mechanically signaled flight controls are replaced by
digital controls
Flight Control Systems
Actuation Systems
47. Propulsion System
Engines - Rolls Royce Trent UltraFan
Offers at least 20 per cent better fuel burn and CO2
emissions than the first generation of Trent engine
Increased bypass ratio to 15:1
48. Alternative Jet Fuel
Bio-SPK – 50/50 Blend of Jet A fuel and Jatropha Oil
Jatropha Oil
From Jatropha Curcas plant – resistant to drought and
can be planted in desert climates; can grow anywhere
Compatible with current aircraft systems
Engine ground tests showed reduction in fuel flow due
to higher heat of combustion
Could possibly reduce carbon emissions by up to 80%
49.
50. Approach
Identified and addressed holes in systems and
processes that currently are in use.
Incorporated existing materials, technology and data
analysis technique to improve airplane designs and
maintenance processes/programs
Expected results is a overall improvement to not only
maintenance but operational efficiency as well.
51. Listed improvements could extend major maintenance
by 25%
Use of Composite Material in airplane design
Redesign of Turbine Engine Blades
Improve capabilities of Boeing’s Airplane Health Management
System (AHMS)
Improvements in Maintenance Programs
Condition Based Maintenance: based on data collected and
analyzed from (AHMS)
use of “Machine Learning”.
Key is some improvement require time to see results
Improvements
52. Composites
Composites materials consist of a fibrous
reinforcements bonded together with a matrix
material
Allows the stiffness and strength of the material to
change with direction of loading
53. Composites
Beneficial characteristics
Heat Resistance
Weighs less than traditional materials
Corrosion resistance
Strength and durability
Part consolidation
A single piece made of composite materials can replace an entire
assembly of metal parts.
55. Composites
Most efficient use of advanced composites in aircraft
structure is in applications with:
Highly loaded parts with thick gages.
High fatigue loads
Areas susceptible to corrosion
Critical weight reduction
Major part of heavy maintenance is structural
inspections.
Expanding the use of composites can contribute to
improvement and expanding on inspections intervals
56. Turbine Engine Blades
Build hollow turbine blades
Being developed at Iowa State University
Benefits
Coolant is blow through an arrangement of holes
Creates a cooling film between the blades
Reduces heat, allowing blades to retain there shape and strength.
Better cooling equals fuel savings, longer lasting parts, cuts cost
• Improvements could reduce maintenance and inspections
57. Airplane Health Management
System
What is it?
Airplane Health Management System uses real-time airplane data to
provide enhanced fault forwarding, troubleshooting, and historical
maintenance information.
• Valuable decision making support tool
Fix or fly mentality
58. Enhancements
Current capabilities
Engine monitor/flight parametric data such as fuel flow, fuel mileage,
thrust deviation.
• Enhancements
Pinpoint vibrations
Expand system to include flight controls and structural vibration monitoring.
• Why flight controls and structural?
Detection depends entirely on crew
Response to vibration is a exercise in airmanship
Monitoring and reducing vibrations can reduce structural fatigue. This
could lead to reduction in schedule and unscheduled maintenance repair
time and cost
Extend structural intspections
Identifying and correcting the cause of in-flight airplane vibration often is accomplished
through trial and error, which can consume many maintenance hours (Hence pinpoint
vibrations)
59. Results
• AHMS = reduction in schedule interruption, increase
in maintenance and operational efficiency.
Valuable data can be obtain for use in optimizing
maintenance.
• Key
The system and its architecture must be developed with
clear requirements and metrics.
60. Challenges
Requires a strong commitment
Looking passed upfront cost and seeing future savings
System development is an intensive and time
consuming process
Results may take years
61. Improve Maintenance Programs
• Boeing currently conducts a review of maintenance
processes
Improve the process
• How?
Incorporate AHMS data
Develop and system which
incorporates machine learning
62. Improve Maintenance Programs
Optimization of maintenance programs will be based
on:
Results from analysis
Fleet Trends
Real world outcome
Evaluation of 400 task on Boeings 777
Resulted in the extension of the maintenance inspection
intervals.
63. DATA!
• Power of Data
Statistical approach
More methods of analyzing data than one can imagine
• System requirement?
Data and than more data
Must be good data (garbage in garbage out).
Current Boeing method relies on the
Collection of Service data
Analysis of Service data
Both Positive and Negative
Results
Provides necessary information to make decisions and
recommendation
64. Enhanced Maintenance Programs
Take it one step further
Use AHMS data
Machine Learning “Big Data”
Use machine learning to optimize a predictive maintenance
schedule
65. MACHINE LEARNING
Machine learning
Part of artificial intelligence, concerns the construction and study of
systems that can learn from data.
Some machine learning systems attempt to eliminate the need for
human data analysis, while others adopt a collaborative approach
between human and machine.
Uses algorithms to learn from data.
Aids in identification of key trends that otherwise may be missed
Can contribute to the modification of maintenance programs to
improve efficiency
68. Requirements Verification
• Passenger transport
• This aircraft can operate as a commercial passenger carrying flight and an
extended range of passenger carrying operations.
• 250 – 400 passengers depending on configuration
• Aircraft can carry a maximum of 305 Passengers
• Operating altitude = 50,000 ft
• Cruise altitude is at 50,ooo ft
• Reduced fuel consumption, 20% less than 777
• Fuel consumption is 20% less per engine
• Range min 4500nm
• Aircraft range is 4500nm
• High speed subsonic M=.95
• Aircraft cruise speed is in High subsonic region at M=0.9
• Major maintenance span increased 25% over B777
• Major maintenance span increased
70. References
Bertin, John J., and Cummings, Russell M., Aerodynamics for Engineers, 5th Ed., Pearson,
New Jersey
Component Weights." n.d. Document. 15 September 2011.
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Allen, Mike. "Alternative Fuels to Gasoline - Cost of Alternative Fuels - Popular Mechanics."
Automotive Care, Home Improvement, Tools, DIY Tips - Popular Mechanics. Popular
Mechanics, 1 May 2006. Web. 19 Oct. 2011.
<http://www.popularmechanics.com/cars/alternative-fuel/news/2690341>.
"Jatropha Advantages - Benefits." PlantOils.in - The Home of Plant Oils Online. Oil from
Jatropha. Web. 19 Oct. 2011.
<http://www.plantoils.in/portal/jatropha/add/adv/adv.html>.
Kinder, Dr. James D., and Timothy Rahmes. "Evaluation of Bio-Derived Synthetic."
Evaluation of Bio-Derived Synthetic. The Boeing Company, June 2009. Web. Oct. 2011.
<http://www.ascension-publishing.com/BIZ/Bio-SPK.pdf>.
Raymer, Daniel P. Aircraft Design: a Conceptual Approach. Washington, D.C.: American
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Rolls Royce UltraFan. Rolls Royce. Web. 12 Mar. 2014. < http://www.rolls-
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